Mortar board cap



April 7, 1959 E. J. OREILLY l 2,880,423

MORTAR BOARD CAP Filed Feb.'s, 1954 4 sheets-sheet 1 INVENTOR. favs/,4R0 .7: oRf-/Lz Y April 7, 1959. E. J. oRElLLY 2,880,423

MORTAR BOARD CAP Filed, Feb. 5, 1954 4 SheeCS-Sheeil 2 1N VEN TOR. 0 WARD J. 0725/.4 L Y T Tak /vA-'K April 7, 1959 E. J. OREILLY v2,880,423

MORTAR BOARD CAP Filed Feb. s, 1954 4 sheets-sheet 4 TmMf-TYS I vthe covered board is a crown or cap piece.

United Stts Patet MORTAR BOARD CAP Edward J. OReilly, New London, Ohio, assignor toThe C. E. Ward Company, Newr London, Ohio, a corporaj tion of Ohio .Application February 3,l 1954, Serial No.r 407,842

3`Claims. (Cl. 2'192) This invention relates Igenerally to -caps and the like and more particularly to mortar board caps.

-' 'Mortar' caps have heretofore been made by inserting a cardboard stiffener intoA a cloth covering. Attached to This structure has a number of disadvantages which have rresulted in poor serviceability and high expense. Since the Vstifener for the mortar board onl the topy section is made of -cardboard, it has been dii'cult or impossible to clean the caps when they become stained because the cardboard insert would be destroyed by the cleaning solutions. Because of the nature of use, normally a mortar board cap is only worn by any given individualV once and it is highly desirable to beable` to clean thezcap` each time it is used. One of the more practical methods of cleaning clean the textile'materialand re-assemble the'cap. This, of course, involves a largewamountof labor anditis very unsatisfactory. f l

It ,isz animportant object. of'this inventionto provide a cap containing a stitfener'whereinthe lstiffener `is not detrementally affected by cleaningsolutions.

...It is another objectof this inventionto providev a mortar Iboard cap which may be easilyr cleaned-,without disassembling the cap.

It is another object of this invention to provide a cap which is substantially immune to stains and easilycleaned.

It is another object ofthis invention-to provide a cap which may be ,easily fabricated by low-costhigh production methods of manufacture.

It is still another object of vthis `invention to provide a light-weight structure fora reinforced cap which can be easily cleaned and which is not susceptible tov damage due .to handling.

Itis stillY anotherobject of this invention tof'provide a mortar board cap wherein a piece of fiber glass'isutilized as'jthe stitener.

' :Further objects and'y advantagesv will appear from the following description and drawings, wherein:

-Fig.v` l4 isfa perspective View of a finished mortar board cap according Ato this invention;

Fig.,.2ais a view` of therst step in the assembly `of thel cap showingthe outer portion of the crown;

. Fig.v 3 is a partial cross sectionshowing the method of connectingthe crown to `the mortar .board covering;

Fig. 4 is a view showing the forming of the crown liner;

Fig. 5 is a cross section of the completed crown liner; Fig. 6 Vis a cross-sectional view of a completed Vmortar `board cap;

Fig. 7 is apartial cross-sectional` view ofA avmodilied form `of. mortar board;

,.2 Fig. 1l is a cross-sectional view ofthejig and'fwelding `apparatus shown in Fig. 10,shown withy amortar; board cap positioned readyefor welding; l y

Fig. 12 is an enlargedfragmentary crossfsection showing the position ofthe elements fwhen the `actual,welding OCCUI'S.

Fig. 13 is a cross-sectional view of amodified-form of mortar board;

Fig.; 14 is a view showing'. the elementsvofthis modified formY of mortar board;

Fig. 15 is a plan viewof the reinforcing-. andwretaining members shownin Figs. 13 and-14;

Fig. v16 is an'enlarged fragmentary crossfsection;show` ing the position` of` thee'elements; at the;` time-off-met`a1 stitching; and

Fig. 17 is an,,enlargedfragmentaryfview offthestructure shown in Fig. 7 yat the point `where the -crowntis'attached to the mortar board.

A mortar board according to'this invention is-fabric`ated from materials which may be easily cleaned with vanygfof the standard cleaning processes and materials. Preferably, the material is a `plastic relatively impervious tomoisture penetration. Three embodiments are'shown, in the first of which a fiberglass insert is provided-for the stiifener of the mortar board whichis covered with. aplastic -material embossed with a broadcloth surface. v"Theor-own is also formed of plastic material, ythe outer surface of which is embossed with al broadcloth texture, theliner of which is embossed `with a tufted design. The -crown is attached to the lower mortar board coverl by welding the plastic material. In the second embodiment of'this invention, the board per seis moldedin-sectionsrthe board and is formed with an outwardlyv extending flange.

The crown in this embodiment is secured to the mortar board by .means of elasticor `draw strings which draw the upper-edge of thecrowninward'underneath'the flange on the mountingmernber.I Inlthis-embodiment the crown may be removed from the-mortarboardif desired,4 for either the purposes of cleaningY or mounting a` different size crown. ln the third embodiment of this invention, the board is made up of two sheets of "fiber glass reinforced plastc material. These'two sheets are sealed together about the perimeter with polyester resin and lunder heat and Vpressure until the resin is cured. The board is then coveredvwith poplinor rayon material. The crown is positionedin place, a retainer of fiberglass' reinforced plastic material is inserted inside the crown ,and the Vcrap is stitched together with metal stitches.

Referring to the drawings, lthe flnishedpmortarv board cap 10 has an appearanceas shown in Fig. l and isformed of several sub-assemblies. The crown 11 itself, whichvis attached to the mortar board proper, isV formed withan outer portion and a liner. In order to form `the, outer portion 12 of the crown, two pieces of vinyl plastic having a profile substantially as in Fig. 2 are placed together with their outer surfaces adjacent to each other. They. are then welded together along the seams- 13 and 14. vv In the preferred embodiment these two pieces are weldedY vinyl plastic is used which is embossed with a broadcloth nish so that it will appear to be made of a textile fabric while being immune to stains and easily cleaned.

The outer portion 12 of the crown is then turned inside out to place the embossed side out and the seams in and is slipped over a form 16 which is preferably wood. As is apparent in Fig. 3, the outer portion 12 has a generally cup-shaped appearance and is positioned with the small end at the lower end of the form 16. The outer portion 12 is proportioned so that the lower edge fits beneath the heating element 17 so that it may be welded thereby to the lower surface 1S of the mortar board portion. The lower surface 18 is also formed of a sheet of vinyl plastic embossed with a broadcloth surface and is positioned on the welding table 19 with a sheet of phenolic resin 21 therebetween. Electrical power is then applied to the heating element 17 and welding table thereby welding the outer portion of the crown to the under surface 18 of the mortar board. The phenolic resin 21 prevents scorching or burning of the vinyl along the weld and assists in the production of a neat weld.

The liner 22 of the crown portion is also formed of vinyl plastic, however, in this case it is desirable to use a sheet of plastic embossed with a tufted design which will give the appearance of quilting or the like. Here again two sheets having a shape generally shown at Fig. 2 are welded together along the seams in the same manner as the outer portion. The cup-shaped liner is then inserted into the center of a cylindrical heating die 26 as shown in Fig. 4 with the lower edge projecting outwardly adjacent to the lower edge of the die. The liner is not turned inside out as the seams should be on the outside. Here again a at sheet of tufted vinyl 27 is positioned on the welding table 28 with a sheet of phenolic plasticr29 therebetween. The liner is then inserted into the outer portion of the crown and fastened in place around the lower opening by means of sewing, welding or any other suitable means. In the preferred form, the liner 22 is sewed to the outer portion 12 with a seam tape 36. It is preferable to form all crowns 11 with the same dimensions at the point where they are vfastened to the mortar board so that a single welding die can be used and by merely changing the contours approaching the lower opening it is possible to achieve a large variety of hat sizes. The liner 22 is welded to the flat sheet 27 thereby forming the completed cupshaped liner shown in Fig. 5.

The assembly shown in Fig. 3 comprising the outer portion 12 of the crown and the lower sheet of the mortar board 18 is then placed against a sheet of stiifening plastic 31 which is preferably iber glass plastic since ber glass plastics provide greater strength with little Weight, and the upper surface of the mortar board 32 is welded to the lower surface 18 around the outer edge of the stiening plastic 31. The stiffening plastic 31 is thereby totally covered by the covering plastic which is embossed with a broadcloth surface. The preferred form of the apparatus used to weld the edges of the plastic covers around the stiffening plastic 31 is shown in Figs. l0, 11 and l2 wherein a rectangular heating element 51 is mounted on a metallic mounting plate 52. The heating element 51 is preferably copper and surrounds a wooden form 53. The form 53 is formed with a central aperture 54 adapted to receive the crown portion 11 and properly center it. The upper surface of the jig 53 is spaced below the upper surface of the heating element 51 and a sheet of sponge rubber 56 is positioned in the cavity thereby formed. The sponge rubber is also formed with a central aperture similar to the aperture 54. The lower surface 18 is then positioned over the heating element 51 and jig 53 with the attached crown 11 extending into the aperture 54. The stiiening plastic 31 is then positioned over the Vlower surface 18. The aperture 54, of course, serves to locate K the lower surface 18 and the edges of the stiening plastic 31 are located by the heating element 51. The upper surface 32 of the mortar board is then positioned above the stiifening plastic 31 and tension is applied by the clamps or tape 57. Above the upper surface 32 a thin sheet of phenolic resin 53 is positioned to insure a good weld. The upper plate 59 is then brought into contact with the phenolic resin 53 compressing the lower surface 18 and the stiffening plastic 31 against the sponge rubber 56 until the upper surface and the lower surface 1S come into contact. The Various elements assume the position shown generally in Fig. 12 at this time. Electric power is then supplied to create the weld between the upper surface 32 and the lower surface 18 and the excess plastic is trimmed away. By utilizing this structure a uniform weld is insured and proper relationship of al1 the elements is accomplished.

In the preferred embodiment the stiffening plastic is provided with a central aperture 33 through which a button 34 may be fastened.

Since the mortar board stiffener 31 is formed of a plastic which is immune to injury from cleaning solutions and the like and since all the exposed portions of the cap are formed of stain-resisting plastics, it is a simple matter to just wipe off any dirt smudges which might be present and the necessity of disassembling is completely eliminated. Since the bond created by the welding is moisture proof, moisture is also prevented from entering the cap itself.

If desired, the liner and the outer surface of the crown section may be welded together in some decorative de` sign as at 37 and openings 3S cut through to provide ventilation into the crown proper.

Another form of this invention shown in Figs. 7, 8, 9 and 17 comprises a mortar board molded in two parts.. The upper part 41 is formed with an upper surface embossed with a textile design such as broadcloth and the: lower surface provided with stiffening ribs 42. A centrally located boss 43 is also molded into the upper part 41 and is adapted to receive the cup-shaped crown mount-- ing member 44. The lower surface member 46 is molded with a flat conical shape adapted to fit the lower edge of the ribs 42 and is secured against the upper part 41 by welding or other means to form the mortar board. In this embodiment, the crown 47 may be formed of plastic in the same manner as previously described, or of textiles. However, in this embodiment, the crown is open at both ends and is not permanently axed to the mortar board but is slipped over the flange member 44 and is secured thereto by means of elastics, drawstrings, or the like. The edges of the liner and outer coversl in the embodiment may be welded together in the case of plastics or by sewing if textile materials are used. This structure has the advantage of permitting exchange of crowns so that proper crown sizes are available without the necessity of maintaining large stocks of mortar boards.

The third form of this invention shown in Figs. 13, 14 l5, and 16 comprises a mortar board made up of two pieces of fiber glass reinforced plastic sheets 60 and 61 sealed together about the perimeter 65 with polyester resin and cured under heat and pressure. One piece 61 has an opening 62 at the center. After the two pieces are sealed together, the board is covered with a fabric material 63 which is sewn up in the general shape of an envelope. The flap is then machine tacked locally to complete the covering. The crown 64 is then positioned relative to the board, and a retainer 66 of ber glass reinforced plastic sheeting is inserted into the crown. This retainer has a matching circular opening 67 at the center. Through this opening is insertedA the clinching plate 68, of a metal stitching machine. The machine is then activated, the head 69 comes down and stitch 71 is made through retainer 66, crown 64, lower side of covering 63 and'lower sheet of board 61. This is repeatedl six to eight times equally spaced about retainer 66. This process assembles the cap securely yet eliminates any roughness from the clinched ends visible on the top of the board since the clinch is made inside or between sheets 60 and 61. The liner is then attached in the same manner as described above in connection with the first embodiment.

Although preferred embodiments of this invention are illustrated, it will be realized that various modifications of the structural details may be made without departing from the essence of the invention. Therefore, except insofar as they are claimed in the appended claims, structural details may be varied widely without modifying this invention. Accordingly, the appended claims and not the aforesaid detailed descriptions are determinative of the scope of the invention.

What is claimed is:

1. A mortar board cap comprising a tlat, square, lightweight, self-sustaining plate of water impervious fiber glass, thin, flexible, sheet material stretched over and encompassing the edges and substantially the entire upper surface of said plate and extending inwardly against the lower surface of said plate from each of the edges thereof, forming a mortar board, said plate being formed with a central aperture, a decorative button secured to the upper surface of said mortar board having a shank extending through said flexible sheet material and having fastening means extending into the central aperture in said plate, and a crown having side walls shaped to tt the head of a wearer and a top wall secured centrally to the lower surface of said mortar board and covering the central zone thereof containing the aperture in said plate and said fastening means, said crown being formed of inner and outer plies of material, said inner ply being composed of flexible plastic material and extended over the entire inner surface of the crown, said mortar board projecting laterally in every direction beyond said crown, and said flexible sheet material covering at least all portions of the under surface of said plate which project laterally beyond said crown.

2. A mortar board cap as defined in claim 1 with said crown having Ventilating openings formed therein.

3. A mortar board cap as defined in claim 1 with said flexible sheet material and the outer ply of said crown being of a plastic material.

References Cited in the le of this patent UNITED STATES PATENTS 224,745 Trested Feb. 17, 1880 1,934,114 Brander Nov. 7, 1933 2,112,383 Sloan et al Mar. 29, 1938 2,312,227 Yant Feb. 23, 1943 2,424,279 Libshutz et al July 22, 1947 2,556,016 Turshin June 5, 1951 2,629,874 La Maida Mar. 3, 1953 2,677,827 Lockhart May 11, 1954 

